KZ550 ltd air box swap?

Hello all!
I've been scouring this site researching info on my bike, 1981 KZ550 ltd c-2.
When I got the bike it did not run at all.
There was no airbox and the carb filters were literally foam squares zip tied to the carb intake.
Thanks to forum member loud I rewired the bike and got it to turn.
I have put pods on it and bigger main jets and had it running great.....once.
Now it won't start without choke and even then it doesn't want to run for long.
I have been trying to find an air box to put back in it and take that route but have had little luck.
Does anybody know of a different model that may fit in place of the kz550 stock model?
Maybe the kz750? Or the 1000?
They both look similar.

The 1000s are wrong and all the 650 ones I have seen wouldnt work either, depending on what type of carbs (slide or CV) you have they may be different as well

Airbox. Partzilla diagrams: probably 80-83 KZ550-A, 550-C, 81 550-D1.
The other 550 airboxes are quite a bit different & may not fit into the frame.

KZ550 Info. KZR member loudhvx Motorcycle Stuff page

Carburetor choke flaps. loudhvx TK22 page --- click --- then scroll down.

Not even a KZ550 A model will fit.
The later LTD's used bigger carbs, so they won't work.

You will have to get the KZ550 C model airbox.

But if the bike used to run, and now doesn't, then the problem may not be just the airbox.

First check compression, then check valve lash if you haven't done so in a while. READ the valve warning before checking the valves. It's very important.

Check for vac leaks. Make sure the pilot jets are clean and clear. Check fuel levels.

Those TK22 carbs will almost always need choke to start when the motor is cold. If not, then the jetting is too rich.

Yeah it ran great but just the one time.
Carbs are clean and choke flaps are fine too.
I had read on another forum of a guy that put 120 keihin main jets in his so I tried that and once I got everything tuned in that's when it ran for a night.
A few days later I pull it out for ride and it won't stay running.
I know it needs new cylinder gaskets and planned on that rebuild this winter.
Are those mains too big?
If so then can anybody tell me jets that they used?

Calebjkd wrote: ...it won't stay running....

Are valve clearances within specs?

Good Fortune!

If you are still looking for an airbox, I have the stock one off my 81 KZ550 C. It has no boots, just the plastic box.

Found a box and boots on CL.
Just needs the top cap.
I'm gonna try and make the pods work though and keep the box as a backup.

Im not sure about valve clearances.
My riding season is pretty much over anyway and i have limited time to work on my bikes so a top end rebuild and getting the pods working are going to be my winter project.
Anything else that needs done also to get it running right.
I also have a '71 Yamaha XS650 that I'm working on so I've plenty to keep me busy.

Here's what I'm working on.
Pods aren't on the bike in this pic.

ChicagoLTD

What do you want for your air box?

What did you drill your jets out to for the pods?

That's a good lookin bike in the profile pic man>

Check your pilot jets. Use a guitar string to clear them If they're not open than the bike won't run for S--t. If it sat for a long time clear the choke jets too.
Steve

The TK22 doesn't have an enricher circuit (choke jet).

For pods, you will need adjustable needles. Either the dynojet ones or adjustable factory needles available in most rebuild kits. For a starting point, try 98 mains, needle clip at the third groove from the top (on either type of needle), and 34 pilots.